Smokeless furnace

ABSTRACT

A biomass fired boiler having a series of inverted U-shaped exhaust gas flues. Water from a collection tank is pumped and sprayed onto deflection plates in the towers. The exhaust gases progressively commingle with the droplets to extract heat energy and collect contaminants at the tank until all the smoke has been absorbed into the water. The heated water is re-directed through a thermal exchanger of the heat transfer system and heat energy is reclaimed. Floating and/or suspended contaminants are filtered and/or collected and appropriately removed and/or incinerated.

RELATED APPLICATION DATA

This is a non-provisional application of provisional application Ser. No. 60/923,823, filed Apr. 17, 2008.

BACKGROUND OF THE INVENTION

The present invention relates to biomass fired boilers and, in particular, to a high-efficiency boiler that can be fired with a variety of alternative combustible fuels (e.g. wood, coal, waste, byproducts, pellets, corn, petroleum waste, gas, oil or other organic material) and wherein the exhaust gases are conducted through a shower system to absorb the exhaust gases (i.e. smoke), reclaim the exhausted heat and clean contaminants from the gaseous effluent.

The present invention was developed to provide a heating system wherein exhaust gases from a boiler/stove/furnace are passed through a moist environment created by a shower system to absorb the exhaust gases (i.e. smoke), reclaim the exhausted heat and clean carbon dioxide and other contaminants from the gaseous effluent. The shower system comprises a serpentine series of gravity towers (e.g. inverted U-shaped) that channel the exhaust gases; expose the gases to a moisture rich environment (e.g. water droplets and mist); and collect the heated water in a collection tank. The exhaust gases are passed through a humid environment of patterned water droplets and mist that is formed in the towers to absorb the exhaust gases, heat energy and contaminants. The heated water is gravity collected at the collection tank and successively reduced concentrations of exhaust gases are passed to each successive tower. A portion of the heated water is re-circulated through the towers. The remainder of the heated water is filtered, cleaned of effluents and circulated through the liquid heat transfer system associated with the boiler/stove/furnace and/or a secondary thermal transfer system. Solid effluents and contaminants are skimmed, filtered and/or collected, incinerated or otherwise disposed.

SUMMARY OF THE INVENTION

It is a primary object of the invention to provide a high efficiency fuel fired heating system.

It is further object of the invention to provide a boiler system wherein exhaust gases are conveyed through a shower system comprised of a serpentine series of conduits (e.g. towers) fed with gravity water showers.

It is further object of the invention to provide a series of inverted U-shaped towers that communicate with a liquid (e.g. water) supply and collection tank.

It is further object of the invention to provide a system wherein each inverted U-shaped tower includes a spray forming assembly such as a deflector to form droplets and mist that absorb and cleanse the exhaust gases.

It is further object of the invention to provide a closed system wherein pumps, valves, filters, skimmers, sensors and electro-mechanical servos operate to control and direct water flow from the collection tank to the spray towers and thermal transfer assembly(s); monitor water temperature, water level and collected effluent and contaminants; and channel the gases through each tower until the gases are fully absorbed and solid effluents and contaminants are collected, burned or otherwise disposed.

The foregoing objects, advantages and distinctions of the invention are obtained in one construction of a biomass fired boiler and associated liquid heat exchange system. Combustion exhaust gases or smoke formed in the burn chamber(s) of the boiler are coupled via a primary flue to a closed system defined by a sequential series of inverted U-shaped towers disposed above a water collection tank. Water from the collection tank is pumped and sprayed onto deflection plates in the towers. The exhaust gases commingle with the droplets and mist to heat the water and extract heat energy, effluents and contaminants contained in the smoke.

Residual gases are successively channeled from the collection the tank to each tower until fully washed and only vapor remains. A portion of the heated water is re-circulated through the towers. The remainder of the heated water is filtered and circulated through the heat exchanger and thermal transfer system coupled to the boiler and heat energy is reclaimed. Floating and/or suspended contaminants are filtered, skimmed and/or collected and appropriately removed and/or incinerated. Thermal transfer coils may also be included to extract heat at the collection tank.

In an alternative system construction, the exhaust gases might be conducted through the water at the collection tank (e.g. in the fashion of bubbling) prior to being conducted to the next adjacent tower.

Still other objects, advantages, distinctions, constructions and combinations of individual features of the invention will become more apparent from the following description with respect to the appended drawings. Similar components and assemblies are referred to in the various drawings with similar alphanumeric reference characters. The description to each combination should therefore not be literally construed in limitation of the invention. Rather, the invention should be interpreted within the broad scope of the further appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a system block diagram to the construction of the smokeless furnace or heat transfer system and wherein the spray towers are shown in partial cutaway to expose internal assemblies.

DESCRIPTION OF THE PREFERRED EMBODIMENT

With attention to FIG. 1, a system diagram is shown to the present novel and inventive heating system 2. The system 2 includes a boiler/furnace 4 that can be fired with a variety of combustible fuels (e.g. wood, coal, oil, gas, byproducts and other organic/biomass materials). The fuel is burned in an associated burn chamber(s) and heat energy is released and absorbed into a liquid heat transfer media (e.g. water, water/glycol mixture etc.) circulated through an associated closed loop, heat exchanger system 4. The heat exchanger 4 is located in close thermal transfer proximity to the burn chamber(s) and most typically surrounds all or a portion of the burn chamber(s). The combustion heat is transferred to the liquid media and the media is circulated from the internal or external heat exchanger 4 to a conduit/radiator system 5 that directs the liquid about the heated premises.

The heat exchanger 4 can include internal exhaust conduits (not shown) that channel the smoke within or about the burn chamber to an associated chimney or flue 6. The conduits can be located in the burn chamber or in the heat exchanger 4 but are positioned such that the liquid thermal transfer media is in thermal contact with the conduits to most efficiently extract heat contained in the exhaust gases.

Whereas conventional boilers release a portion of the heat energy to the environment with the smoke or exhaust gases, the present improved heating system 2 directs substantially no smoke or exhaust gases to the environment. Essentially all the exhaust gases and any heat energy in the exhaust gases is captured and any contaminants contained in the effluents are collected and safely processed to prevent a negative impact on the environment.

The exhaust gases are particularly exposed to a liquid shower or wash system 8 where the exhaust gases are absorbed into a liquid media and the heat is reclaimed and any contaminants are collected. The reclaimed heat trapped in the spray water is combined and re-circulated with the liquid media of the thermal transfer exchanger 4.

Turning attention to the upper regions of the boiler 2, exhaust gases are conducted from the flue 6 to the shower system or washing assembly 8. The gases can enter the flue 6 at temperatures approaching 900° F. The assembly 8 provides a number towers 10 of appropriate length, height, and cross-sectional shape and diameter to treat the exhaust gases until completely absorbed. Two inverted U-shaped, cylindrical towers 10 are presently provided. The towers 10 project from a cover or canopy assembly 12 of a lower lying liquid holding tank 14. More or less towers 10 can be adapted to accommodate any particular system. The towers 10 can be constructed to a variety of shapes and orientations, although a gravity supported construction for reclamation of the water is preferred.

A supply of liquid 16 (e.g. water) is contained in the tank 14 to a level that permits the exhaust gases to flow above the water 16 from one tower 10 to the next. The towers 10 can be constructed to alternative shapes and can be arranged as desired to appropriately direct the liquid 16 and gases into the tank 12 and between the towers 10. The exhaust gases are conducted between and through the towers 10 due to normal thermal and pressure differentials and/or provided baffles (not shown) and/or fans (not shown) fitted to the towers 10 or tank 12.

The water or other appropriate liquid 16 stored in the tank 14 is directed via one or more pumps 18 and a conduit system 20 into the towers 10. Valves 22 located along the piping of the conduit system 20 control the flow of liquid into the towers 10.

A portion of the liquid 16 is sprayed to impinge or strike baffles 24 fitted inside the towers 10. The baffles 24 break up liquid spray into droplets and mist that fall back through the towers 10 to the tank 14. The baffles 24 can be positioned at any desired deflection angle, can be constructed of a variety of materials that withstand the environment, and can exhibit a variety of shapes and surfaces defined to produce the most advantageous spray patterns for optimal smoke absorption. The baffles 24 can be solid or porous and can exhibit any geometric shape that facilitates the formation of the desired droplets and mist. The baffles 24 are normally located near the tops of the towers 10, although can be located anywhere along each tower 10. Multiple baffles 24 can also be located in each tower 10.

Exhaust gases in the towers 10 mix with the droplets and mist to heat the liquid spray and extract heat, particulates and other contaminants emitted with the gases. For flue gases approaching 900° F., the liquid 16 in a nominal 70 cubic foot tank 14 can be elevated to 160° F. As the smoke is absorbed, the droplets and mist fall under the influence of gravity back into the tank 12. Any solid materials vented from the flue in the smoke (e.g. ash, soot, heavy metals) are held in the tank 14 and typically collect at the top of the liquid 16, settle to the bottom or are suspended as particulates.

The liquid 16 is maintained in the tank to a level that forms a space 26 between the top of the liquid 16 and the cover or canopy assembly 12. The channel space 26 can be in the range of 8 to 18 inches. The channel space 26 allows the exhaust gases to flow from the boiler 2 and sequentially into each of the towers 10. As noted at FIG. 1 the gases are depicted to be denser (i.e. darker) nearer the boiler 4 and progressively less dense as each tower 10 is traversed, until only water or steam is emitted from the exit port 28 of the rightmost tower 10.

The cover or canopy 12 can be constructed of plastic, stainless steel or other suitable materials or composites resistant to the working environment. Suitable conduits, baffles or fans can also be provided in the space 26 to direct the gases between the towers 10. Conduits might also be provided in the space 26 to direct a portion of the exhaust gases directly into the liquid 16 in the tank 14 in the fashion of a bubbler to facilitate the extraction of heat and contaminants.

The leftmost tower 10 also includes a bracket 28 that supports the tower 10 and weight of the intersecting flue piece 6. A funnel piece 30 mounted to the bottom of the leftmost riser portion of the tower captures the falling water and prevents a downward draft and flow of exhaust gases into the tank 14 rather that up and into the series of towers 10.

Distributed about the liquid containment tank 14 are a number of sensors or electrodes. A sensor 32 (e.g. a float) monitors liquid depth. Another sensor 34 monitors liquid temperature. Another servo 36 (e.g. solenoid valve) cooperates with the sensor 32 to admit additional liquid 16 into the tank 14. Yet another servo 38 can cooperate with the sensor 34 to circulate the heated liquid 16 into the heat exchanger 4 and conduit/radiator system 5.

The heat extracted from the exhaust gases and stored in the liquid 16 is returned to the heat exchanger 4 via the conduit system 20 and/or to the external thermal transfer conduit/radiator system 5. The liquid 16 is normally separately treated for acidity and other chemical changes. Also added to the liquid 16 to soften the water and enhance smoke collection is a mixture of soda (e.g. Sal soda) and a sudsing agent (e.g. tide soap).

A separate heat exchange coil 7 coupled for example to a domestic hot water system might also be mounted in the tank 14 to heat the domestic water. Supply and return air ducts or conduits 9 and 11 of a heating, ventilating and air conditioning system at the premises (HVAC) might also be fitted to the cover 12 to humidify a supply of air passed through the tank 14 in the space 26 adjacent a smoke free portion of the space 26 and returned to the heated premises.

As mentioned, effluents frequently collect on the surface of the liquid 16 in the form of a floating moss or agglutination of contaminants. These flotsam materials are skimmed off the liquid 16 with rotating paddles assemblies 40 and 42. The assemblies 40 and 42 presently each provide several laterally displaced paddle arms or any desired shape that project from an axle that is rotated to cause the paddles to direct the surface effluent to a collection point or chute. The effluent may also collect as suspended particulates in the liquid 16. Rake tines, an auger, strainer or a variety of other assemblies may alternatively or in combination with each other be used to periodically draw the solid effluents from the liquid 16.

The collected materials can be dried and then conveyed to a separate incinerator or back to the burn chamber at the boiler 4 to be re-burned. Alternatively, the materials can be disposed of through other suitable means or mechanisms.

Also provided at the tank 14 is a filtration assembly 44 that can take a variety of forms. Appropriate filter media and supports can be appropriately located about the tank 14. The filtration assembly 44 can be selected to filter any desired contaminant, soot, heavy metal, or any other chemical or particulate found in the spray liquid 16.

A system controller 50 (e.g. microprocessor based) can be coupled with suitable conductors or wirelessly to monitor the foregoing liquid level and temperature sensors 32 and 34, filter assembly(s) 44 and collected effluents. The controller 50 can direct the servos 36 and 38, as well as monitor water clarity, surface debris and direct any associated filtration assembly 44 or the skimmer assemblies 40 and 42 and/or any collector or incinerator assembly that might be provided to collect, remove or incinerate collected contaminants or effluents. Alternatively, a conveyor (e.g. auger based) can be provided to direct the collected debris back into the burn chamber of the furnace 2.

While the invention is shown and described with respect to a presently preferred assembly and several considered improvements, modifications and/or alternatives thereto, still other assemblies and arrangements may be suggested to those skilled in the art. It is to be appreciated therefore that the features of the disclosed heating system can be arranged in different combinations. For example, the towers can be serially coupled or coupled in parallel to the collection tank. Contaminant filters and/or a rake or skimmer assembly can be fitted to the tank to extract suspended contaminants. The primary thermal transfer assembly or a separate assembly (e.g. radiator) can be coupled to the tank. The foregoing description should therefore be construed to include all those embodiments within the spirit and scope of the following claims. 

1. A heating system comprising: a) a combustible fuel fired furnace including liquid thermal transfer means for extracting heat from combusted materials and transferring the heat to a circulated liquid and exhaust means for exhausting combustion gases; and b) exhaust treatment means for receiving exhausted combustion gases and conveying the gases through a liquid rich atmosphere to extract exhausted heat and contaminants in the gases and vent substantially only moist vapor to the environment.
 2. A system as set forth in claim 1 wherein said exhaust treatment means includes a hollow tower coupled to receive said combustion gases and coupled to a lower lying collection container containing a wash liquid, wherein the wash liquid is directed into the tower to commingle with the combustion gases under the influence of gravity to heat the liquid and extract solids from the gases, and wherein the liquid is coupled to said liquid thermal transfer means.
 3. A system as set forth in claim 2 wherein said furnace includes an exhaust flue, wherein said exhaust treatment means comprises a cylindrical, inverted U-shaped tower coupled to said exhaust flue to receiving said exhausted combustion gases, wherein said tower includes a baffle and onto which a stream of wash liquid is directed, and wherein said baffle converts the liquid to form droplets and mist.
 4. A system as set forth in claim 3 including a second cylindrical inverted U-shaped tower, wherein at least the input ends of the first and second towers project from a cover mounted to said collection container, wherein the level of wash liquid in the collection container is maintained to provide a space between the cover and liquid whereby the exhaust gases can flow from an output of the first tower to an input of the second tower.
 5. A system as set forth in claim 4 including means for filtering the wash liquid of suspended particulates and contaminants.
 6. A system as set forth in claim 4 including means having a plurality of paddles mounted to rotate to skim materials floating on the wash liquid, collect and incinerate the skimmed flotsam.
 7. A system as set forth in claim 4 wherein said collection container includes thermal exchanger means for directing the wash liquid over the thermal exchanger means to extracting heat reclaimed in the wash liquid and re-circulate the reclaimed heat via a media passed through the thermal exchanger means.
 8. A system as set forth in claim 4 including means for circulating a supply of air over the space between the cover and liquid to moisturize the air and convey the air to the heated premises.
 9. A system as set forth in claim 2 wherein said wash liquid comprises a mixture of water, soda and a sudsing ingredient.
 10. A heating system comprising: a) a combustible fuel fired furnace including liquid thermal transfer means for extracting heat from combusted materials and transferring the heat to a circulated liquid and an exhaust flue for exhausting combustion gases; and b) first and second hollow towers projecting from a cover mounted to over lie a collection container containing a wash liquid, wherein at least one of said first and second towers is coupled to said exhaust flue and including means for conveying the exhaust gases through said first and second towers, wherein the wash liquid is directed into the first and second towers to commingle with the combustion gases under the influence of gravity to heat the liquid and extract solids from the gases and vent substantially only moist vapor to the environment, and wherein the liquid is coupled to said liquid thermal transfer means
 11. A system as set forth in claim 10 wherein said furnace includes an exhaust flue, wherein said exhaust treatment means comprises a cylindrical, inverted U-shaped tower coupled to said exhaust flue to receiving said exhausted combustion gases, wherein said tower includes a baffle and onto which a stream of wash liquid is directed, and wherein said baffle converts the liquid to form droplets and mist.
 12. A system as set forth in claim 10 wherein said first and second towers comprise cylindrical inverted U-shaped conduits, wherein at least an input end of each of the first and second towers project from said cover mounted to said collection container, wherein the level of wash liquid in the collection container is maintained to provide a space between the cover and liquid whereby the exhaust gases can flow from an output of the first tower to an input of the second tower.
 13. A system as set forth in claim 10 including means for filtering the wash liquid of suspended particulates and contaminants.
 14. A system as set forth in claim 10 including means having a plurality of paddles mounted to rotate to skim materials floating on the wash liquid, collect and incinerate the skimmed flotsam.
 15. A system as set forth in claim 10 wherein said collection container includes thermal exchanger means for directing the wash liquid over the thermal exchanger means to extracting heat reclaimed in the wash liquid and re-circulate the reclaimed heat via a media passed through the thermal exchanger means.
 16. A system as set forth in claim 10 including means for circulating a supply of air over the space between the cover and liquid to moisturize the air and convey the air to the heated premises.
 17. A system as set forth in claim 10 wherein said wash liquid comprises a mixture of water, soda and a sudsing ingredient. 